Colin's FJ1200

[FJ1200W]

Colin dropped off the replacement tachometer moments ago.
Disassembling the cluster, I had to think about it.
Threaded, not pressed.

[FJ1200W]

Decided to install the new used gauge cluster.
Took about a half an hour to strip the bike down.
The old gauge set (bottom in pic) had a bad tachometer.
Installed the replacements, noticed a few differences.
Different top speed.
White needles vs red.
Put the bike back together, fired it up, tachometer works great.
Wish the same could be said for the neutral light.
Bet it's the bulb....

[FJ1200W]

Happy Thanksgiving!

[FJ1200W]

So the bike just could not go back with the neutral light.
I tore it down last night and if you can replace the meter bulbs without removing the meter, you're a better tech than I.
The 1st bulb to be replaced was the neutral light, and much to my surprise, there was no bulb there.
Whatever. Now we know why it didn't work.
Four other bulbs were bad, so all of them were replaced.
12v 3.4w Stanley #158 mini wedge miniature bulb, for those wondering "I wonder what kind of a bulb it was".
Suzuki part number 09471-12028
The 09471-12082 are the same bulb, but "HD" or "Long Life" and those I'll put in my FJ.
The 9471-12077 is a half dimmer, 1.7w vs 3.4w
As luck would have it, I found these buried in a tote full of parts.
I have too many parts, but at times like this, I'm grateful.
Shifting gears -
---------------------------------------------------------------------------------------------------
We lost a young man far too early.
Skylar and I worked together at a powersports dealer, and he found the ultimate position in a smaller, local shop.
He just returned, with the entire crew of the shop, from a "business" trip to Daytona Beach. Sure looks like everyone had more than a fun time.
Then this -
Godspeed Skylar
https://www.komu.com/news/midmissourinews/columbia-woman-charged-in-fatal-hit-and-run-on-providence-road/article_3d87cb1a-52c9-11ec-8586-a7b68e6b4d4f.html

[FJ1200W]

Hopefully finished.
Still more to do, but I've done all I want.
I did wire the fuel pump into the fuel reserve switch by the chock knob.
Should be able to flip it off and run the carbs dry.
Oh, JIS bit worked flawlessly on the nearly stripped choke retaining screw.

[Troyskie]

Great stuff mate!

[FJ1200W]

Thank you, the owner has been super patient 
He rides a Harley but does down this FJ and three more as well

[ribbert]

Thank you, the owner has been super patient 
He rides a Harley but does down this FJ and three more as well

Hey Steve, how come no fuel line clips?

Noel

[FJ1200W]

Good question Noel.
There is one clip at the fuel pump, that's where I want the line removed there, so the other connections are difficult.
I did use the removable clamps on the filter though, making it removable.
Sure is fast and easy to remove and install.
One does have to make sure the shut off valve stays off -
Oh, I connect the fuel valve with zip strips to the frame where I've added a silicone bumper.
I do that just to keep it from working around.
Even with the wires protected at wear points, I like the added security of a secured fuel line.

[FJ1200W]

Time to replace the factory petcock.
Phucker leaked.
Luckily not while being ridden.
Amazing how those filters swell when soaked by gas.
So here is my $40 solution.

[FJ1200W]

New petcock is installed, I went out today and replaced the fuel line, removing the 2nd valve and tidy things up.

I noticed one of the pod air filters had distorted from earlier fuel contact, to the point I'm wanting to replace it.

Advise?

I'm not sure why they would not be fuel resistant, no matter.

His forks and triple clamps might be my next project, I dunno, one other bike to fix for another and then I'm "free"!

[FJ1200W]

Here is the filter we had the problem with.
Fuel dripped on the "rubber" portion of the filter, causing it to swelled up.
The problem was the swollen filter would not stay on the carburetor.
We tried using hose clamps over a period of days to re-shrink it, and it helped, just not enough.
Local unleaded alcohol free premium on this one.

[fj1289]

Try spraying some hairspray into the cap from the can.  Then spread some around the inside of the filter and maybe some around the outside of the carb throat.  Gently attach it - just e nouns to let the hair spray "tack up" with the filter in place.  The next day snug the filter clamp down - don't over tighten or it generally wants to squeeze the filter off.  This is sort of like the old trick of using hairspray to install new handlebar grips.  With luck and heat and time, maybe the rubber will shrink back down a bit!

[FJ1200W]

Try spraying some hairspray into the cap from the can.  Then spread some around the inside of the filter and maybe some around the outside of the carb throat.  Gently attach it - just e nouns to let the hair spray "tack up" with the filter in place.  The next day snug the filter clamp down - don't over tighten or it generally wants to squeeze the filter off.  This is sort of like the old trick of using hairspray to install new handlebar grips.  With luck and heat and time, maybe the rubber will shrink back down a bit!

Worth a try, thanks!

[Old Rider]

I know boiling in hot water will reshape rubber that has swollen in gasoline.i have done it on carbfloat gaskets and some other things i cant remember now .Not sure if i can recomend it on your podfilters do it at own risk...